Floor tile compositions from petroleum resins



United States Patent FLOOR TILE COMPOSITIONS FROM PETROLEUM RESINS John F. McKay, In, Cranford, and Anthony H. Gleason,

Westfield, N. 1., assignors to Esso Research and Engineering Company, a corporation of Delaware No Drawing. Application December 22, 1952 Serial No. 327,410

3 Claims. (Cl. 260-41) This invention relates to improved resin compositions and, more particularly, to novel compositions composed of petroleum resins and isoolefin polymers and copolymers and to such compositions .especially adapted for use in. f,

floor tile formulations. It is known that hydrocarbon resins can be produced from certain refinery streams containing olefins and di- {olefins by a variety of methods such as polymerization using Friedel-Crafts catalysts. Steam cracked streams have been found especially useful for this purpose. The resins produced from certain fractions, however, have softening points that are generally too low for certain applications, such as, for example, in floor tilecomposigraded the color of the resins. This is undesirable since light colored resins are premium materials. In fact, substantially the only way the low melting point resins can be used at present is as extenders for the more expensive high softening point resins such as the coumarone-indene resins. Post-polymerization treatment of the resins having low softening points can be used to raise the resin softening points to levels where good filing may be made but these modifications add to the cost of the resin and, in

, some. cases, degrade resin color.

Therehas now been discovered a process whereby novel mixtures of petroleum resins with .isobutylene polymers] and isobutylene-diolefin copolymers can be prepared and employed as floor tile formulations. The polymer added to the mixture is used instead of the pitch type plasticizer -=ordinarily employed. No post-polymerization treatment of the resin is required.

Hydrocarbon resins to which the present invention is applicable, are made by treating ahydrocarbon mixture containing 10 to 35% diolefins and 30 to 65% olefins and 0 to 60% of aromatics, paraffins, and naphthenes with 0.25-2.5% of a Friedel-Crafts type catalyst such as aluminum chloride, aluminum bromide, boron trifiuoride, and

the like, or solutions, slurries or complexes thereof. A

hydrocarbon mixture suitable for resin production is conveniently found in hydrocarbon streams obtained by steam cracking gas oils. The cracked streams used as a feed for making the resin have boiling ranges between 20f"'and 280 C., or may be composed of any intermediate fraction selected from this range. The reactions are conducted at temperatures in the range of -100 to 100 (preferably 35 to +'65 C.), Residual catalyst is quenched by suitable methods, suchas addition of methyl alcohol and subsequent filtration, or by water and/or caustic washing. Washing with aqueous acid mayalso 'be'*used.--"lhc final solution is then s ripped ot unre- 2,823,194 Fuentes Feb. 11, 1 5

acted hydrocarbons and low molecular weight oils by vacuum or steam distillation. The product is a substantially non-aromatic, unsaturated hydrocarbon resin. The petroleum distillate resins synthesized by this method usually have softening points lower than 95 C.

The rubbery polymer component of the novel formulations may be either a homopolymer of an isoolefin having from 4 to 8 carbon atoms or it may be a copolymer of an isoolefin of 4 to 8 carbon atoms with a diolefin having from 4 to 8 carbon atoms, preferably a conjugated diolefin such as butadiene, isoprene and dimethylbutadiene. The isoolefin-diolefin copolymers may be made by the disclosure of U. S. 2,356,128. The polymers having a major proportion of isobutylene and minor proportionof: a conjugated diolefin such as isoprene and butadiene are'known generally as butyl rubber. These polymers and copolymers are made by the polymerization of olefinic feeds with Friedel-Crafts catalysts at controlled temperatures.

The exact amount of the polymer or copolymer required to give optimum tile qualities depends on the softening point and consistency of the resin. Generally, the amount of rubbery plasticizer used varies between 10 and 50 weight percent based on the amount of petroleum resin. As an illustration, with 15 parts of a resin softening at C., 3.5 parts of polymer can be advantageously used. Five parts of polymer may be used with 15 parts of a resin softening at C. The molecu- Material: Parts by weight Petroleum hydrocarbon resin (soft. pt. 82 C.) 15 Isobutylene-isoprene copolymer 4 Titanium dioxide 3 Asbestos 39 Marble d 39 The copolymer rubber is thoroughly mixed with the resin binder on a rubber mill at about F. The temperature is then raised to about 300 F. and the filters are added and mixed. The stock may then be either sheeted from a calendering mill in tile form or it may be molded into tiles in a press. Mixing of the stock may also be accomplished in a Banbury mixer or any other suitable mixing or kneading device.

Other materials examined as plasticizers for low softening resins in tile compositions do not give tiles meeting specifications in all respects. Failure in indentation occurs when the plasticizer is increased to the point where the tile just passes flexure and impact requirements. Among the plasticizers which were tried with negative results are the pitch types and aromatic types.

Only a small amount of polymer or copolymer relative to total tile composition is required to give proper balance to tile properties. High molecular weight isobutylenediolefin copolymers and olyisobutylene are effective in the compositions although normally such materials are not considered as plasticizers.

The employment of these compositions for producing asphalt floor tiles from low melting petroleum resins gives other desirable properties to the tiles which are not obtained whenconventional pitch-type plasticizers are used with high melting coumarone-indene resins, for instance. The combination of low melting hydrocarbon -resins together with rubbery polymers in the compositions of the invention gives a high degree of ductility or internal cohesiveness to the tiles. This greatly reduces breakage of the tiles during laying operations and reducesthe danger of cracking due to subsequent impact.

EXAMPLE 1 Hydrocarbon streams containing olefins, diolefins, aromatics, and saturated hydrocarbons obtained by steam Furthermore, the resin polymer tile binder has a very 5 cracking of gas oils were polymerized in the presence high viscosity index. This permits tiles to be formulated of a Friedel-Crafts type Catalyst The resins were having room temperature indentation values on the high covered by stripping 011 the unreacted hydrocarbons by end of the scale permitted by specifications and still fallvacuum dlstlllation. Analysis in each case indicated that ing below the maximum value permitted for 115 F. the resin was of an essentially non-aromatic structure, indentation test. This means that such tiles have excel- 1 since little or none of the aromatic constituents of the lent foot comfort (are less tiring to walk on), yet have feed entered the composition. Polymerization data are excellent resistance to indentation by heavy furniture, summarized in Table I.

Table I Run No 1 2 3 4 5 6 7 s 0 Approx. Bolling Pt. C.) 20-48 20-125 38-130 48-130 30-280 s5200 Composition, Wt. Percent (Approx):

Diolefins a0 20 19. 4 12 15 15 Olefins 60 4s 50. 6 50. 9 s2 45 Aromatics:

Benzene 25 22 28. 5 4. 5 Toluene. 6 7 7. 6 10. 1 10 Higher 7.2 Paraflins, N aphthenes 1 1. 2 16 Polymerization:

Cata st A1013 A1013 A1613 A1013 A1013 BFQ A101; A101; BF; Temperature C.) 15 100 45 25 25 20 Resin, Wt. Percent -85 25-35 19 30-35 18-23 15 20-30 10 11 S.Pt. (O.) -85 70-90 66 85-95 95 74 -100 05 76 The exact softening point and yield depend upon the degree of work-up of the resin, such as stripping conditions, etc.

Softening Points determined by ASTM E-28-51-T.

The data in Tables II and III illustrate the invention. It can be seen that the experimental floor tiles embodying the improved composition pass specifications on indentation, flexure, impact resistance, and curl resistance. The tiles also have adequate soap and caustic resistance. Typicalvdata are also included in Tables 11 and III for tiles made from low softening resins with conventional pitch-type plasticizer to show that such tiles do not pass the specifications. The compositions are based on parts by weight of, floor tile. The rest of the tile is'composed of inert fillerssuch as asbestos, marble dust-and pigment.

T able II.-Tile compositions Isobutylene-Iso- Polyisobutylene prene Copol. Pitch Resin, 1 Composition Plasti- Resin, Soft.

Number cizer, Parts Pt., 0.

Parts M. W. X Parts M. W. X Parts 1 Ring and ball method (ASIM E-28-51'1).

Table lII.--T1le evaluations McBurney Indent., mils Flexure, Impact 77 F Inches-at Resist- Curl, Inches F Break once 30 sec 1 min 10 min.

v26 0.00 Pass all Federal '24 0.00 Specifications.

33 Do not pass all Fed- 51 (tail)--- d eralSpecifications.

8 57 (fail)... 1 Federal Specifica- 38 max.... 0.03 max.

tions for Asphalt Tiles (SS-T-306a).

EXAMPLE 2 Table IV below shows data on a number of tile formulations which were made up and tested. The tile 6 What is claimed is:

l. A floor tile composition which consists essentially of the milled admixture of parts by weight of a petroleum resin prepared by polymerizing in the presence of a Friedel-Crafts catalyst a steam-cracked distillate boiling in the range of to 280 C. and consisting essentially of 10 to diolefins, 30 to 65% olefins, and 0 to 60% aromatics, parafiins, and naphthenes; 2 to 7 parts by weight of an uncured rubbery polymer having a molecular weight between 7,000 and 200,000 and selected from the group consisting of polyisobutylene and the copolymer of a major proportion of isobutylene and a minor proportion of isoprene; and 78 to 83 parts by weight of Table I V.-Evaluati0n of floor tiles from resins and rubbery polymers Tile Formulation, parts Tile Evaluations l Resin Rubbery Plasticizer MeBurney 1ndent., mils Tile No. Soit.

Pt., Flexure, Our}, 0. Resin 77 F. inches, at Impact Inches Parts Material Molecular 115 F Break Weight 30 sec 1 min. 10 min.

15 2 Copolymer I 50, 000 14 2.0 15 3.5 do ,000 9 0. 15 4 do 80,000 14 0. 15 4 do 40, 000 9 0. 15 4 .....do 60,000 9 0. 15 4 Oil extended copolymer 9 0. 15 5. 5 Oopolymer 40, 000 11 2. 15 6 do 1 40, 000 11 2. 15 4 Polyisobutylene- 40, 000 11 1. 15 7 .-do 60, 000 9 0. 15 7 do, 40,000 8 0. 15 5.2 do 9,000 18 1. 15 2. 5 Natural Rubber 11 1. 15 4 Butadiene-styrene copolymen 16 0.35 (fell) 15 5. 5 Butadiene-acrylonitrile copoly- 10 0.2 (ia1l) do mer. 15 6 Isobutylene-styrene copolymer-- 5 do l 15 4 Copolymer 2 40, 000 3 .do '15 7 do 40,000 4 5 (fall). do .02 15 9 50,000 6 6 (fa-11).... do

1 Federal Specifications for Asphalt Tile (SS-T-306a) I Copolyxner used was isobutylene-isoprene copolymerization product known as butyl rubber.

I Coumarone-indene resins Oopolymer extended with 13% Forum 40 oil by mill mixing before tile formulation.

EXAMPLE 3 inert inorganic filler of the class consisting of titanium dioxide, asbestos, marble dust, and mixtures thereof.

2. A composition according to claim 1 wherein the rubbery polymer is polyisobutylene.

3. A composition according to claim 1 wherein the rubbery polymer is a copolymer of a major proportion of isobutylene and a minor proportion of isoprene.

Table V.-Flo0r tile evaluation Tile Formulation McBurney Indent., mils Tile No. Resin Plastleizer 77 F. Flexure Impact Curl,

115 F., (inches) Inches 30 sec. Parts PtSuit. Parts Type 1 min. 10 min.

15 63 2. Copolymer 9 13 23 00 15 77 4 d 1 10 14 28 00 15 5. 5 7 10 18 00 15 I 112 12 12 17 22 .6 0..-..- .00

l Isobntylene-iso rene copolymer. I Ooumarone-in ene resin.

References Cited in the tile of this patent UNITED STATES PATENTS 2,234,660 Thomas Mar. 11, 1941 2,356,128 Thomas et a1. Aug. 22, 1944 2,500,755 Jones Mar. 14, 1950 2,523,150 Schneider et a1. Sept. 19, 1950- 2... s s new 9*. a

---- my a. 1951 

1. A FLOOR TILE COMPOSITION WHICH CONSISTS ESSENTIALLY OF THE MILLED ADMIXTURE OF 15 PARTS BY WEIGHT OF A PETROLEUM RESIN PREPARED BY POLYMERIZING IN THE PRESENCE OF A FRIEDEL-CRAFTS CATALYST A STEAM-CRACKED DISTILLATE BOILING IN THE RANGE OF 20* TO 280*C. AND CONSISTING ESSENTIALLY OF 10 TO 35% DIOLEFINS, 30 TO 65% OLEFINS, AND 0 TO 60% AROMATICS, PARAFFINS, AND NAPHTHENES, 2 TO 7 PARTS BY WEIGHT OF AN UNCURED RUBBERY POLYMER HAVING A MOLECULAR WEIGHT BETWEEN 7,000 AND 200,000 AND SELECTED FROM THE GROUP CONSISTING OF POLYISOBUTYLENE AND THE COPOLYMER OF A MAJOR PROPORTION OF ISOBUTYLENE AND A MINOR PROPORTION OF ISOPRENE, AND 78 TO 83 PARTS BY WEIGHT OF INERT INORGANIC FILLER OF THE CLASS CONSISTING OF TITANIUM DIOXIDE, ASBESTOS, MARBLE DUST, AND MIXRTURES THEREOF. 